Filter Mat for the Passage of Contaminated Air

ABSTRACT

The invention relates to a filter mat, which is used in applications where it filters the flows of contaminated air that pass through it. In such mats, there are points where aerosols collect. This is disadvantageous as it lowers the efficiency of the mat. The present invention overcomes this by having, at these points, wicks ( 2 ) that absorb said collections.

The present invention is based on a fibre mat for the cleaning ofcontaminated air. Contaminated air passes through the fibre mat from itsfront to its back. During this passage, solid particles and drops ofliquid (designated as aerosols) are absorbed. These absorbed particlescan concentrate at certain points in the filter mat. Consequently, thefibre mat's cleaning efficiency is lowered because these parts of thefibrous mass then prevent passage of contaminated air. The resultantincreased pressure drop across the filter is a great disadvantage.

Depending on the type of contamination, different types of filter arerequired for filtering oil-laden air not only from lathes, millingmachines, drills, grinders and hardened drilling tools, but also frommachines used in cold rolling, hot rolling, hot forming, die casting,wire drawing and the manufacture and machining of rubber, plastic and soon. In the foregoing application areas, the air flow through the filteris large, normally between 500 and 200,000 m³ per hour. The filtershould be able to withstand continuous use. This means that, for atleast one year, and without stoppages for draining and cleaning, it mustbe able to filter air that contains aerosols, usually between 0.5 and100 mg per cubic metre of air. The filter must be self-draining. Thismeans that the oil trapped by the filter has to be drained while thefilter is still in use and with the served machinery still running.Throughout its entire service life, the filter should, when filteringemulsion aerosols and oil aerosols, have a collection efficiency ofbetween 80 and 98 percent. The collection efficiency can be measuredusing instruments such as the “Dust Track TSI”. Furthermore, the filtershould be washable and capable of being reused at least five times.

Provided that it can trap the contaminants in the air passing throughit, the filter can be of any type whatsoever.

Fibres are a suitable material for filters. Glass fibres of less than 20micrometres are to be preferred. Glass fibres with a fibre size in therange of 3-12 micrometres are particularly suitable. Fibrous materialcan be held together by needling. In this process, needles are stuckinto the material, thereby pulling some of the surrounding fibres withthem. These fibres take up a transversal alignment and hold the materialtogether, even after the needles have been pulled out. As the fibreshave been needled securely to each other, rather than joined using abonding agent, the risk of auto-ignition in the oil filter isconsiderably reduced.

The present invention is based on the foregoing data and its aim is toeliminate the collections of aerosols that occur in the filter mat. Thelatter problem is solved by connecting wicks to the filter mat's backsurface at the points where it is calculated that the above-mentionedaerosols collect. Said wicks must be able to attract the collections sothat the fibre mat retains full efficiency. The wicks can be rods,plaited tubes or threads. Preferably, they should be made of a materialthat achieves a surface tension that results in the desired drainingproperties. Wick width, thickness and length are tailored to produce thedesired effect. It has proven particularly suitable to make the wicks ofa needled, glass fibre material. Even more particularly, it has provensuitable to use folded fibre mats where the wicks are placed at thepoints where the fibre mat changes direction. It is advantageous for thefibre mat to have a more or less vertical alignment.

Further details of the present invention are given in the patent claimsbelow.

Design examples of the present invention are given in the attacheddrawing where:

FIG. 1 shows a filter mat with wicks;

FIG. 2 shows said mat from the side;

FIG. 3 shows a different design of the fibre mat and wicks; and,

FIG. 4 shows a folded fibre mat and its wicks.

FIGS. 1 and 2 show a basically vertical fibre mat with three wicks (2)where both the fibre mat and the wicks can be made of needled glassfibres of the above-stated dimensions. The liquid aerosols that collecttowards the lower end of the fibre mat are sucked up by the wicks at thebottom of the fibre mat.

FIG. 3 shows a fibre mat that comprises two walls. In FIG. 4, the fibremat has been folded and, at the lower end of its folds (5), equippedwith wicks (2).

The use of wicks eliminates liquid from the fibre mat so that the latteris fully functional at all times.

Fibre mat wicks can be made replaceable. Consequently, thanks to the useof wicks, each fibre mat can be used considerably longer.

The essence of the present invention is that the fibre mat and the wicksshould be of such materials that the fibre mat attracts aerosols and thewicks attract the aerosols that reduce fibre mat efficiency.

It is obvious that the use of a wick-equipped fibre mat reduces aircleaning costs because, amongst other things, it is less expensive tochange wicks than it is to replace a whole filter.

The great advantage of the arrangement in the present invention is thatthe pressure drop across the filter is reduced. This, in its turn, hasthe great advantage that it lowers energy consumption.

1. Filter mat for the passage of contaminated air, in which thecontaminants can be particles and/or drops of liquid (i.e. aerosols),the material between the mat's surfaces being of such a type that asgreat a volume of aerosols as possible is absorbed in the mat, the wholebeing, characterised by the back of the mat having one or more wicks toremove absorbed aerosols from the mat.
 2. Fibre mat as per patent claim1, characterised by the possibility of the wicks having a rod, network,thread, tube or plait like character.
 3. Fibre mat as per patent claim1, characterised by one or more of the wicks being replaceable.
 4. Fibremat as per patent claim 1, characterised by the width, thickness andlength of the wicks being such as to give a predetermined absorption. 5.Fibre mat as per patent claim 1, characterised by the absorption of thewicks being controlled by the surface tension of the material in thewicks.
 6. Fibre mat as per patent claim 1, characterised by the wicksbeing placed where aerosols collect.
 7. Fibre mat as per patent claim 1,where the fibre mat is folded, characterised by the wicks being placedwhere mat changes direction.
 8. Fibre mat as per claim 1, characterisedby the mat assuming a position that is more or less vertical.
 9. Fibremat as per claim 1, characterised by the mat and/or wick (s) being madeof a fibrous material such as glass fibres that, preferably, are heldtogether by needling.
 10. Fibre mat as per patent claim 9, characterisedby the fibres in the fibrous material being of a size less than 20micrometres.
 11. Fibre mat as per claim 1, characterised by the mathaving a thickness of between 3 and 40 mm.
 12. Fibre mat as per claim 1,characterised by each wick being securely attached.